Container with tamper-evidence, reclosure feature

ABSTRACT

A container formed from an integral blank with a configuration having a top section and a bottom section attached to each other by a first line of weakness such that upon the application of sufficient pressure, the first line of weakness breaks the attachment of the top section from the bottom section. Upon breaking the attachment, a cover is formed from the top section that is hingedly attached to the bottom section at the rear wall panel. A releasable locking device having a first locking member on the cover is attached by a second line of weakness to a second locking member on the front wall portion. The first locking member and second locking member is in an aligned relationship such that when the second line of weakness is broken, the cover pivotally moves to the open position and a recess is formed between the front panel and side panels and the inner body portion. When the cover pivotally moves from the open position to the closed position, the first locking member and the second locking member engage to secure the inner body portion with cover in a closed relationship. Optionally, an audible sound is emitted when the first locking member engages with the second locking member.

FIELD OF THE INVENTION

[0001] The present invention relates to folding carton containers. More particularly, it is concerned with a sealed container having a hinged cover that may be opened and subsequently reclosed, i.e., “flip-top.” Reclosure engages locking members that not only secures the cover to the container, but results in an audible noise as well. Additionally, the container includes a tamper-evidence feature.

BACKGROUND OF THE INVENTION

[0002] Flip top containers are known in the art. Such containers include a cover or top that is hingedly connected to the top edge of a wall of the container. It is also known that such containers may provide various locking mechanisms or devices for securing the cover to the container after the cover has been initially opened. In other words, after the seal affixing the cover to the container has been broken, the locking mechanism holds the cover in a closed position. Some representative containers of this type are illustratively disclosed in U.S. Pat. Nos. 3,191,848, 3,378,188, 3,893,614, Re 26,471, 3,294,309, 3,295,742, and 4,215,783.

[0003] Although numerous flip-top containers have been proposed, most suffer from various disadvantages and shortcomings. Such disadvantages include complexity of carton making equipment required and difficulty in opening the cover due to, e.g., tearing, ripping, bowing, and the like, poor protection of the contents of the container during transportation and warehouse stacking, unsatisfactory engagement of locking members because the attachment of the locking members is too loose or too tight, which can result in the displacement of product to the outside of the container.

[0004] Thus, as seen, there is a need for a flip-top container that provides adequate protection during transportation and storage, yet easily and cleanly opens. What is also needed is a flip-top container that offers not only a reclosable cover, but provides tamper-evidence protection as well.

SUMMARY OF THE INVENTION

[0005] A container formed from an integral blank with a configuration having a top section and a bottom section attached to each other by a first line of weakness such that upon the application of sufficient pressure, the first line of weakness breaks the attachment of the top section from the bottom section. Upon breaking the attachment, a cover is formed from the top section that is hingedly attached to the bottom section at the rear wall panel. A releasable locking device having a first locking member on the cover is attached by a second line of weakness to a second locking member on the front wall portion. The first locking member and second locking member is in an aligned relationship such that when the second line of weakness is broken, the cover pivotally moves to the open position and a recess is formed between the front panel and side panels and the inner body portion. When the cover pivotally moves from the open position to the closed position, the first locking member and the second locking member engage to secure the inner body portion with cover in a closed relationship. Optionally, an audible sound is emitted when the first locking member engages with the second locking member.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006]FIG. 1 is a plan view of a blank for forming the container of the present invention;

[0007]FIG. 2 is a perspective view of the formed container with the cover closed;

[0008]FIG. 3 is a perspective view of the formed container with the cover open; and

[0009]FIG. 4 is an enlarged view of the line of weakness in FIG. 2.

DETAILED DESCRIPTION OF THE INVENTION

[0010] According to the present invention, a flip-top container is provided that is formed from an integral, e.g., a single, blank. The container has bottom, front, rear, and side panels, and a cover or top. Locking members are provided at the upper edge of the front wall panel and on the corresponding inner surface of the cover. The locking members on the wall panel and the cover are in cooperative relationship to one another to retain the cover in a closed position after opening.

[0011] The present invention also relates to a unopened flip-top container having top and bottom sections affixed or linked to one another by a continuous line of weakness, wherein the container top section can be pivoted about an integral hinge formed with the rear wall panel of the bottom section, i.e., hingedly attached. Opening the unopened container is preferably begun by lifting a grasping member, which is located on the cover. Opening an unopened container for the first time results in breaking the continuous line of weakness between the top and bottom sections, thereby creating a cover that is hingedly attached to an upper edge of the rear panel of the container. Thus, any break or other discontinuity along the continuous line of weakness between the top and bottom sections, before the container is opened for the first time, provides an indication of possible package tampering.

[0012] After the container is initially opened, the hingedly attached cover is maintained in closed position using at least one locking mechanism or means. Such locking means has a first locking member and a second locking member, as described more fully below. Preferably, the separate locking members are initially joined together by a continuous line of weakness that is broken upon the initial opening of the cover. After the initial opening and henceforth, the first and second locking members engage upon closing, preferably emitting an audible snap sound.

[0013] Referring to FIG. 1, an integral blank 10 as shown is suitably cut and scored to form container 12 (shown in FIGS. 2 and 3) according to the present invention. Blank 10 includes front wall panel 20 connected to first cover portion 104 and first bottom portion 114 by crease score lines 24 and 26, respectively; first side wall panel 40 connected to second cover portion 102 and second bottom portion 112 by crease score lines 44 and 46, respectively; second side wall panel 50 connected to third cover portion 106 and third bottom portion 116 by crease score lines 54 and 56, respectively; and back wall panel 30 connected to fourth cover portion 108 and fourth bottom portion 118 by hinge score line 34 and crease score line 36, respectively. In one embodiment, crease score lines 44, 46, 24, 26, 54, 56, and 36 and hinge score line 34 are fold lines that have at least one perforation to facilitate the articulation between the respective cover portions and container panels.

[0014] First side wall panel 40 is connected to front wall panel 20 by crease line 48. Front wall panel 20 is connected to second side wall panel 50 by crease line 28. Second side wall panel 50 is connected to back wall panel 30 by crease line 58.

[0015] Although not required, front cover panel 104 may have a larger surface area than cover portions 102 and 106. Additionally, forth cover portion 108 may have edges that are angled and extend upwardly toward its central portion for connecting to first cover portion 104. Such connection may be by any known method, such as adhesive gluing, stapling, heat sealing, hot melt, and the like.

[0016] Container top section 100 (shown in FIGS. 2 and 3) is formed from cover portions 102, 104, 106, and 108. Container bottom section 110 is formed from bottom portions 112, 114, 116, and 118. Container cover portions and container bottom portions can also be referred to as flaps.

[0017] As depicted in FIG. 1, inner wall portions 42, 22, and 52 have corresponding first portions 42 a, 22 a, and 52 a, respectively, and second portions, 42 b, 22 b, and 52 b, opposite thereof, respectively. Upon folding of the blank 10, first portions, 42 a, 22 a, and 52 a, respectively, contact and are securely attached to the inner surfaces of first side wall panel 40, front wall panel 20 and second side wall panel 50, respectively. Consequently, second portions, 42 b, 22 b, and 52 b form the interior upper portion 65 of container 12, as shown in FIG. 3. Recesses or slot openings 43 and 45 are provided at the lower portion of crease fold lines 148 and 128 to provide flexibility to inner wall portions 22, 42, and 52 when attached to the inner surfaces of first side wall panel 40, front wall panel 20, and second side wall panel 50, respectively. In one embodiment, inner wall portions 22, 42 and 52 are secured to panels 20, 40, and 50, respectively, by any means of attachment, including, but not limited to, adhesive gluing, stapling, heat sealing, hot melt, and the like.

[0018] Attached to first inner wall portion 22 is locking device 80 having first and second locking members 82 and 84, respectively, and lines of weakness 84 d, 86, and 88. First locking member 82 may have reinforcing portion 90 a that may be substantially the same shape as grasping member 90. In FIGS. 1-3, reinforcing portion 90 a and grasping member 90 are represented as ovoid in configuration but may have other shapes or configurations as well. For example, grasping member 90 may be circular, straight, or sigmoidal-shaped, and the like. Additionally, grasping member 90 may be a cut-out area, that is, material is removed in certain shapes such as ovoids, circles, square, and the like. Reinforcing portion 90 a may be the same general shape as grasping member 90 and may be slightly smaller than grasping member 90. Upon attachment to the inner surface of front wall panel 20, reinforcing portion 90 a overlays grasping member 90 and reinforces the grasping member when the user initially opens cover 100 (see FIG. 3).

[0019] In an embodiment, first and second locking members 82 and 84, respectively, are located centrally, but any placement may be used as well. Second locking member 84 includes crease score line 84 a, upper edge 85 and sides 84 b and 84 c. Upper edge 85, which can be straight, sigmoidal-shaped, and the like, is affixed to first locking member 82 prior to initial container opening by line of weakness 84 d. While it is preferred that second locking member 84 be integral with first inner wall portion 22, crease score line 84 a may optionally include at least one partial cut on the outer edges. Spaces 87 and 89 represent area wherein material has been removed from first locking member 82 and sides 84 b and 84 c. In a one embodiment, upon initial opening of the container, second locking member 84 articulates along crease score line 84 a. Upon closing cover 100, second locking member 84 engages with first locking member 82, which is attached to front wall panel 20, resulting in an audible sound, e.g., a click or a snap.

[0020] In an embodiment, folding of the blank into a container is made by running integral blank 10 print surface 15 down with 102, 104, 106 and 108 leading into the machine. Inner wall portion 52 and inner wall portion 22 are plowed inwards to inner wall portion 42 and back panel 30 along crease fold line 148. Locking device 80 along with locking member 84 are folded together onto inner wall portion 22 along lines of weakness 86, 84 a and 88. Adhesive, e.g., hot melt or cold adhesive, is applied to inner wall portion inner wall portion 22 such that the lines, dots, or spots of adhesive do not interfere with line of weakness 70. Simultaneously, adhesive spots are applied to the non-printed side 17 of locking device 80. The integral blank 10 is then plowed inwards along crease line 58. Adhesive is then applied to print surface 15 of inner wall portion 42 just below the line of weakness 70. Adhesive is also applied to manufactures joint 41. First side wall panel 40 is folded inwards along crease line 48 to complete folding the container.

[0021] As previously mentioned, container top section 100 (shown in FIGS. 2 and 3) is formed from cover portions 102, 104, 106, and 108 and container bottom section 110 is formed from bottom portions 112, 114, 116, and 118. In a one embodiment, upon folding, portions 102 and 106 are first articulated inwardly with fourth portion 108 being articulated next. Adhesive, or other attachment means, is placed on the print surface 15 of cover portions 102, 106, and 108. First cover portion 104 is articulated inwardly such that first cover portion 104 is secured to cover portions 102, 106, and 108. Cover portions 102 and 106 are initially articulated toward the inner portion of container along crease score lines 44 and 54, respectively. Fourth cover portion 108 and first cover portion 104 are articulated inwardly along crease score lines 24 and 34, respectively. In the one embodiment, outer surface of fourth cover portion 108 is then affixed to inner surface of cover portions 102, 104, and 106. Container bottom section 110 (seen in FIGS. 2 and 3) is formed from bottom portions 112, 114, 116, and 118. Bottom portions 112 and 116 are articulated inwardly along crease score lines 46 and 56, respectively. In one embodiment, side portions 112 and 116 have a smaller surface area than bottom portions 114 and 118 and outer portion of fourth bottom portion 118 is secured to the inner surface of front bottom portion 114.

[0022]FIG. 2 shows container 12 fully assembled and unopened. Except for opening area 94, container top section 100 forms a smooth, continuous surface with container bottom section 110. Upon the initial opening of container by lifting top section 100 and separating from container bottom section 110, a slight recess is formed between wall panels 40, 20, and 50 with second inner wall portions 42 b, 22 b, and 52 b (recess shown in FIG. 3).

[0023] Container 12 has two continuous lines of weakness 60 and 70. As seen in FIG. 1, line of weakness 60 extends from the intersection of first side wall panel 40 and second cover panel 102 furthest away from front wall panel 20 across crease line 48 and ending at opening area 94, which is formed about grasping member 90. Likewise, line of weakness 70 extends from the intersection of second side wall panel 50 and third cover portion 106 furthest away from front wall panel 20 across crease line 28 and ending at opening area 94 formed about grasping member 90. While lines of weakness 60 and 70 may be a straight, sigmoid or otherwise shaped, in one embodiment, the lines of weakness 60 and 70 are curved.

[0024] In addition, lines of weakness 60 and 70 may be perforations, slits, or alternating from slits to perforations, or vice versa, or they may be glue spots corresponding with half-cuts between the inner wall and outer cover. As seen in FIGS. 1, 2, and 4, line of weakness 70 alternates from slit portion 72 to perforation portion 73 to slit portion 74 to perforation 75 and to slit portion 76. Similarly, FIG. 1 shows line of weakness 60 alternating from slit portion 62 to perforation portion 63 to slit portion 64 to perforation 65, and to slit portion 66. While lines of weakness 60 and 70 have symmetrical alternation of perforations and slits as compared to each other, such symmetry is not required.

[0025] Nonetheless, in one embodiment, lines of weakness 60 and 70 have substantially constant resistances to separation along their length. For example, if the continuous line of weakness 60 is a scored line, then it is of constant depth and density. Alternatively, if the continuous line of weakness 60 is a perforated line, the dimensions of the perforation components and the land components residing between adjacent perforation components may or may not be constant. This can be seen more readily in FIG. 4. Properties of the continuous lines of weakness 60 and 70 may vary slightly in the corners of the container to impart strength properties and facilitate opening by the consumer.

[0026] Continuous lines of weakness 60 and 70 can be made using any known mechanical means, such as scoring or perforating; chemical means, such as chemical etching; physical means, such as a laser; or combinations thereof. Each continuous line of weakness 60 and 70 can be a single line, or alternatively a series of lines, such as those that make up a tear strip configuration.

[0027]FIG. 4 is an enlarged view of area 200 of FIG. 2, illustrating one embodiment of the continuous line of weakness 70 having perforation components 96 and land components 98. While only continuous line of weakness 70 is shown in this view, it is understood that continuous line of weakness 60 may be equivalent to continuous line of weakness 70.

[0028] The dimensions of perforation component 96 and land component 98 are preferably adjusted to the material selected in order to ensure protection of the articles prior to initially opening the container top section 100, while also allowing easy and clean opening of the container. In one embodiment, perforation component 96 represents an elongated separation that extends along line of weakness 70 between land component 98. A plurality of perforation components 96 extend along the continuous line of weakness 70 are preferably about 1.5 to about 25 millimeters in length, more preferably about 3 to about 4 millimeters in length. A plurality of land components 98, preferably adjacent to at least one perforation component 96, along the continuous line of weakness 70 are preferably from about 1 to about 4 millimeters in length. Smaller lands often result in failure during container folding and filling. Slit portions 72, 74 and 76 are preferably about from about 10 mm to about 20 mm respectively. Longer slit portions are preferred over shorter slit portions to minimize the force to initially open the container. Combinations of perforation, land, and slit areas will vary for containers of varying sizes and materials. While not required, it is nonetheless preferred that a slit portion is located in line of weakness 70 closed to top section 100. While the preceding has described line of weakness 70, it is understood that line of weakness 60 is similar. Breaking or severing continuous lines of weakness 60 and 70 allows for opening container 12 into two portions, cover 100 and bottom section 110 wherein cover 100 is hingedly attached to bottom section 110, hence creating a flip-top container. By lifting cover 100, articles contained in container 12 can be displayed, i.e, viewed, or dispensed.

[0029] As seen in FIG. 3, when container 12 is assembled, first locking member 82 is affixed to the top of the inner surface front wall panel 20. Second locking member 84 is hingedly connected to crease score line 84 a of first wall portion 22 and articulates into juxtaposition with second surface 22 b. In FIG. 3, upper edge 85 of second locking member 84 is disengaged from first locking member 82 by breaking of line of weakness 84 d when cover section 100 is lifted during initial container opening.

[0030] Grasping member 90 can be optionally employed to aid in separating container top section 100 from container bottom section 110. Preferably, at least one grasping member 90 is employed such that separation of top section 100 from bottom section 110 is commenced from a central position upon lifting or grasping and pulling grasping member 90. More preferably, grasping member 90 is positioned substantially adjacent to lines of weakness 60 and 70. Thus, grasping member 90 can be engaged and begin separating container top section 100 from container bottom section 110 in a single step. Grasping member 90 is defined by flexible line of weakness 92. After initial opening of the container, flexible line of weakness 92 may exhibit a slight resiliency that results in grasping member 90 bowing outwards away for outer surface of front wall panel 20. This bowing assists in facilitating opening of container top section 100 from container bottom section 110. Additionally, the bowing helps to prevent tearing about grasping member 90.

[0031] Grasping member 90 should be of sufficient size and geometry to readily receive at least the tip of one human finger. Alternately, grasping member 90 may be removed. Various other tools, such as a hook, could be inserted into grasping member 90 for separating container top section 100 from container bottom section 110. Because the initial opening of the container requires some force to tear or the lines of weakness, it may be desirable to construct grasping member 90 from a heavy or rigid material to prevent tearing upon the initial opening of the container. In one embodiment, the first locking member 82, including tabular portion 90 a, is adhered to the inner surface of front wall panel 20 to provide thickness and support. In one embodiment, grasping member 90 is of ovoid shape, but may be any convex shape, concave shape, or a combination thereof. It has been found that augmenting the functionality of grasping member 90 may be accomplished by implementing scores at either or both side ends of grasping member 90. Additionally, it is preferred for ease of use that opening area 94 separate grasping member 90 from outer front wall panel 20.

[0032] A representative, non-limiting list of materials useful in constructing the container includes corrugated board (polymeric, paper, and the like), paperboard, paper laminations, chipboard, polymeric sheeting, foam board, and combinations thereof, preferably the material is paperboard. Preferred paperboard is 16 pt or 250 g/m² paperboard, solid bleach sulfate (SBS) or recycled paperboard. Preferably, corrugated board comprises E-flute corrugations.

[0033] Types of adhesive useful in the present invention include hot melt or cold glue adhesives known in the industry and can be applied by any known method, including but not limited to spraying, rolling, or transfer methods.

[0034] The container of the present invention is useful for shipping, storing, and displaying a wide range of articles, including, but not limited to, articles that stand upright, such as writing instruments, such as, pens, pencils, crayons and the like, disposable absorbent articles, such as pantyliners, sanitary napkins, adhesive bandages, and the like, hair care products, skin care products, baby products; and pharmaceutical products. Articles contained in the container of the present invention may be individually packaged, or packaged in groups of at least 2 articles. The individual packaging may be in the form of bottles, cans, pouches, sachets, bags, boxes, tubes, flow wraps, and the like. The container of the present invention may contain a single row of articles, multiple rows of articles or be randomly bulk filled.

[0035] The container of the present invention may optionally contain graphics. Graphics on the outwardly disposed surfaces may illustrate preferred opening instructions. The optionally employed graphics may also relate to the articles inside the container cavity. The graphics may also indicate how the articles inside the container cavity relate to a system in which multiple articles can be combined for use according to various uses and needs. 

What is claimed is:
 1. A container formed of an integral blank comprising: a) an outer body portion comprising: i) a front wall panel, ii) a back wall panel, iii) a first side wall panel, and iv) a second side wall panel, wherein, in an initial configuration, each of the front and side wall panels, respectively, has an upper section and a lower section attached thereto by a first line of weakness in the front wall and side wall panels such that upon the application of sufficient pressure, the first line of weakness breaks the attachment of at least a portion of the upper section from the lower section such that the upper section and lower section are no longer attached along the first line of weakness in the front wall and side wall panels, and the back wall panel having a hinge means, thereby forming a second configuration comprising a cover having a front panel, the cover being hingedly attached to the back wall panel to permit the cover to move from an open position to a closed position along the hinge means; b) an inner body portion comprising: i) a front wall portion having an upper edge, wherein the front wall panel is adjacent to the front wall portion, ii) a first side wall portion having an upper edge, wherein the first side wall panel is adjacent to the first side wall portion, and iii) a second side wall portion having an upper edge, wherein the second side wall panel is adjacent to the second side wall portion; and c) a releasable locking device comprising: i) a first locking member having a receiving area and being affixed to the inner surface of the front cover panel and ii) a second locking member having a flap portion and being hingedly connected to the upper edge of the portion selected from the group consisting of the front wall portion, the first side wall portion, the second side wall portion, and combinations thereof, wherein, in an initial configuration, the first locking member is attached to the second locking member by a second line of weakness, the first locking member and the second locking member being in an aligned relationship such that when the second line of weakness is broken, the cover pivotally moves to the open position and a recess is formed between the front panel and side panels and the inner body portion, and when the cover pivotally moves from the open position to the closed position, the first locking member and the second locking member engage to secure the inner body portion with cover in a closed relationship.
 2. A container of claim 1 wherein the cover further comprises the upper sections of each front, back and side panels when said panels are folded inwardly.
 3. A container of claim 1 wherein an audible noise is produced upon engaging the first lock member and the second lock member to secure the cover in a closed position.
 4. A container of claim 1 further comprising a grasping member along the first line of weakness of the upper and lower sections of the front and side wall panels wherein pulling grasping member in a direction away from the bottom section produces the detachment of the top section from the bottom section along the first line of weakness.
 5. A container of claim 4, wherein the grasping member is ovoid.
 6. A container of claim 4, wherein the grasping member is straight.
 7. A container of claim 4, wherein the grasping member is circular.
 8. A container of claim 4, wherein the grasping member is formed by removing a section of the upper section of the front wall.
 9. A container of claim 6, wherein is first locking member further comprises an ovoid portion.
 10. A container of claim 10, wherein the ovoid portion reinforces the grasping member.
 11. A container of claim 4, wherein the first locking member further comprises a straight portion.
 12. A container of claim 12, wherein the straight portion reinforces the grasping member.
 13. A container of claim 4, wherein the first locking member further comprises a cutout section.
 14. A container of claim 14, wherein the cutout portion reinforces the grasping member.
 15. A container of claim 1, wherein said first locking member is releasably attached to second locking member by the second line of weakness in the initial configuration.
 16. A container of claim 1, wherein the inner body portion further comprises slot openings such that the side wall portions and the front wall portion move inwardly when affixed to said outer body portion.
 17. A container of claim 1, wherein the first locking member comprises a receiving area and the second locking member has a flap portion wherein upon pivoting from the open position, to the closed position, the flap portion engages the receiving portion. 